Hydraulic Brake Block Bore Design for Guided Power Piston Travel
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Solution Overview
Problem
Existing hydraulic power units for vehicle braking systems lack efficient mechanical attachment and hydraulic interconnection of components such as solenoid valves, check valves, hydraulic accumulators, and damper chambers, and do not effectively generate brake pressure using external power.
Innovation Solution
A hydraulic block with a power cylinder borehole containing a power piston, sealed with elastomer seals and lubricated by a brake fluid channel, is used to mechanically attach and hydraulically interconnect these components, and an electromechanical power drive generates brake pressure through an electric motor, planetary gear, and ball screw mechanism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the power cylinder borehole has a larger diameter outside the guide section to allow free displacement of the power piston, then the piston can move without jamming, but the guide section requires precise dimensional control to maintain sealing while allowing movement
Solution Approach 1:
The power cylinder borehole is designed with different diameters in different sections: a smaller diameter in the guide section for precise guidance and sealing, and a larger diameter outside the guide section for free piston displacement. This local variation in geometry allows each section to optimize its function without compromising the other.
Solution Approach 2:
The power cylinder borehole is segmented into distinct functional zones: a guide section with controlled dimensions for precise piston guidance and sealing, and an outer section with larger diameter for unrestricted piston movement. This segmentation allows independent optimization of each zone's characteristics.
2Stability of the object's composition
If the guide section has the same diameter as the power piston for precise guidance, then radial guidance is improved, but the piston may jam due to lack of clearance
Solution Approach 1:
The guide section of the power cylinder borehole is designed with a diameter that is slightly larger than the power piston diameter, providing just enough clearance for reliable displacement while maintaining precise radial guidance. This local dimensional optimization balances guidance stability with movement reliability.
3Stability of the object's composition
If the guide section extends beyond the piston seal to provide extended guidance, then radial guidance is improved, but the risk of jamming increases due to reduced clearance
Solution Approach 1:
The guide section is positioned and dimensioned to extend slightly beyond the piston seal, providing adequate radial guidance while maintaining sufficient clearance to prevent jamming. The local geometry is optimized to balance guidance extension with jamming prevention.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The hydraulic block provides effective mechanical attachment, hydraulic interconnection, and efficient brake pressure generation, ensuring reliable operation and lubrication of components, while allowing for backup muscle power actuation in case of failures.
Implementation Method 1
Through the brake fluid channel, brake fluid from the working chamber of the power cylinder borehole reaches the piston seal for lubrication
Implementation Method 2
The power piston is sealed with a piston seal, in particular a sealing ring, in the power cylinder borehole
Implementation Method 3
an electromechanical power drive generates brake pressure through an electric motor
Implementation Method 4
an electromechanical power drive generates brake pressure through an electric motor, planetary gear, and ball screw mechanism
Implementation Method 5
For generating a brake pressure, the power piston is displaceable in the power cylinder borehole with the aid of a power drive
Data Source
AI summary
A power piston in a power cylinder borehole of a hydraulic block of a hydraulic power unit of a hydraulic power vehicle braking system is only guided radially in an axially delimited guide section. The power cylinder borehole is configured with a larger diameter axially outside the guide section. A brake fluid channel extends through the guide section up to an opening of a brake fluid line.